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Eja 8C
Eja 8C
CHARGING SYSTEM
CONTENTS
page page
8C - 4 CHARGING SYSTEM JA
DIAGNOSIS AND TESTING (Continued)
JA CHARGING SYSTEM 8C - 5
DIAGNOSIS AND TESTING (Continued)
Overcharge Test
FIELD
B+
GENERATOR
WIRE
TERMINAL
PLUG VOLTMETER
8C - 6 CHARGING SYSTEM JA
DIAGNOSIS AND TESTING (Continued)
CHARGING SYSTEM RESISTANCE TESTS PREPARATION
These tests will show the amount of voltage drop (1) Before starting test, make sure battery is in
across the generator output wire from the generator good condition and is fully-charged. See Group 8A,
output (B+) terminal to the battery positive post. Battery for more information.
They will also show the amount of voltage drop from (2) Check condition of battery cables at battery.
the ground (-) terminal on the generator (Fig. 1) to Clean if necessary.
the battery negative post. (3) Start the engine and allow it to reach normal
operating temperature.
(4) Shut engine off.
(5) Connect an engine tachometer.
(6) Fully engage the parking brake.
TEST
(1) Start engine.
(2) Place heater blower in high position.
(3) Turn on headlamps and place in high-beam
position.
(4) Turn vehicle interior lamps on.
(5) Bring engine speed up to 2400 rpm and hold.
(6) Testing (+ positive) circuitry:
(a) Touch the negative lead of voltmeter directly
to battery positive POST (Fig. 2).
(b) Touch the positive lead of voltmeter to the
B+ output terminal stud on the generator (not the
Fig. 1 Generator Terminals terminal mounting nut). Voltage should be no
higher than 0.6 volts. If voltage is higher than 0.6
volts, touch test lead to terminal mounting stud
nut and then to the wiring connector. If voltage is
now below 0.6 volts, look for dirty, loose or poor
connection at this point. Also check condition of the
generator output wire-to-battery bullet connector.
Refer to Group 8, Wiring for connector location. A
voltage drop test may be performed at each (-
ground) connection in this circuit to locate the
excessive resistance.
(7) Testing (- ground) circuitry:
(a) Touch the positive lead of voltmeter directly
to battery negative POST .
(b) Touch the negative lead of voltmeter to the
generator case. Voltage should be no higher than
0.3 volts. If voltage is higher than 0.3 volts, touch
test lead to generator case and then to the engine
block. If voltage is now below 0.3 volts, look for
dirty, loose or poor connection at this point. A volt-
age drop test may be performed at each connection
in this circuit to locate the excessive resistance.
This test can also be performed between the gener-
Fig. 2 Battery Voltage Test—Typical ator case and the engine. If test voltage is higher
than 0.3 volts, check for corrosion at generator
A voltmeter with a 0–18 volt DC scale should be
mounting points or loose generator mounting.
used for these tests. By repositioning the voltmeter
test leads, the point of high resistance (voltage drop)
CURRENT OUTPUT TEST
can easily be found.
The current output test will determine if the
Test points on the generator may be reached by
charging system can deliver its minimum test cur-
either removing the air cleaner housing or below by
rent (amperage) output. Refer to the Specifications
raising the vehicle on a hoist.
section at the end of this group for minimum test
current (amperage) requirements.
JA CHARGING SYSTEM 8C - 7
DIAGNOSIS AND TESTING (Continued)
The first part of this test will determine the com- onds to prevent damage to test equipment. On
bined amperage output of both the generator and the certain brands of test equipment, this load will be
Electronic Voltage Regulator (EVR) circuitry. applied automatically. Refer to the operating manual
supplied with test equipment.
PREPARATION (6) The ammeter reading must meet the Minimum
(1) Determine if any Diagnostic Trouble Codes Test Amps specifications as displayed in the Genera-
(DTC) exist. To determine a DTC, refer to On-Board tor Ratings chart. This can be found in the Specifica-
Diagnostics in this group. For repair, refer to the tions section at the end of this group. A label stating
appropriate Powertrain Diagnostic Procedures man- a part reference number is attached to the generator
ual. case. On some engines this label may be located on
(2) Before starting test, make sure battery is in the bottom of the case. Compare this reference num-
good condition and is fully-charged. See Group 8A, ber to the Generator Ratings chart.
Battery for more information. (7) Rotate the load control to the OFF position.
(3) Check condition of battery cables at battery. (8) Continue holding engine speed at 2500. If EVR
Clean if necessary. circuitry is OK, amperage should drop below 15–20
(4) Perform the previous Output Wire Resistance amps. With all electrical accessories and vehicle
Test (voltage drop test) (Fig. 3). This will ensure lighting off, this could take several minutes of engine
clean and tight generator/battery electrical connec- operation. If amperage did not drop, refer to the
tions. appropriate Powertrain Diagnostic Procedures man-
(5) Be sure the generator drive belt is properly ual for testing.
tensioned. Refer to Group 7, Cooling System for (9) Remove volt/amp tester.
information. If minimum amperage could not be met, refer to
(6) A volt/amp tester equipped with both a battery the appropriate Powertrain Diagnostic Procedures
load control (carbon pile rheostat) and an inductive- manual for testing.
type pickup clamp (ammeter probe) will be used for
this test. Refer to operating instructions supplied BATTERY TEMPERATURE SENSOR
with tester. When using a tester equipped with an To perform a complete test of this sensor and its
inductive-type clamp, removal of wiring at the gener- circuitry, refer to the appropriate Powertrain Diag-
ator will not be necessary. nostic Procedures manual. To test the sensor only,
(7) Start the engine and allow it to reach operating refer to the following:
temperature. (1) Disconnect the sensor from the engine harness.
(8) Shut engine off. (2) Attach ohmmeter leads to the wire terminals of
(9) Turn off all electrical accessories and all vehicle the sensor.
lighting. (3) At room temperature of 25° C (75–80° F), an
(10) Connect the volt/amp tester leads to the bat- ohmmeter reading of 9K to 11K ohms should be
tery. Be sure the carbon pile rheostat control is in the observed.
OPEN or OFF position before connecting leads. See (4) If reading is above or below the specification,
Load Test in Group 8A, Battery for more information. replace the sensor.
Also refer to the operating instructions supplied with (5) Refer to the Removal and Installation section
test equipment. for procedures.
(11) Connect the inductive clamp (ammeter probe).
Refer to the operating instructions supplied with test ON-BOARD DIAGNOSTIC SYSTEM TEST
equipment.
(12) If volt/amp tester is not equipped with an GENERAL INFORMATION
engine tachometer, connect a separate tachometer to The Powertrain Control Module (PCM) monitors
the engine. critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
TEST Trouble Code (DTC) is assigned to each input and
(1) Perform the previous test Preparation. output circuit monitored by the OBD system. Some
(2) Fully engage the parking brake. circuits are checked continuously and some are
(3) Start engine. checked only under certain conditions.
(4) Bring engine speed to 2500 rpm. If the OBD system senses that a monitored circuit
(5) With engine speed held at 2500 rpm, slowly is bad, it will put a DTC into electronic memory. The
adjust the rheostat control (load) on the tester to DTC will stay in electronic memory as long as the
obtain the highest amperage reading. Do not allow circuit continues to be bad. The PCM is programmed
voltage to drop below 12 volts. Record the reading. to clear the memory after 50 engine starts if the
This load test must be performed within 15 sec- problem does not occur again.
CHECK
REPEAT
REPAIR
AND
REFER
8W
REPEAT
TIONS
CONNEC-
VOLTAGE
WIRING
WIRE
BROKEN?
WIRE
REPAIR
TO
OUTPUT
FUSE
BROKEN
WIRING
GOOD?
GRAMS.
OUTPUT
YES
SHORT.
GROUP
AGE
WIRE
TEST
LINK
DIA-
VOLT-
WIRE
TEST
FOR
NO
NO
YES
CHECK
DISCONNECT
CHECK
REPEAT
REPEAT
CHECK
TIONS
STARTER
SHORT
CUIT
SHORT
FOR
VOLTAGE
IN
CONNECTOR
DROP
FUSE
YES
WIRE?
WIRING
VOLTAGE
AT
FEED
MOTOR,
NO
CIR-
REPAIR
BLOWN
OUTPUT
CIRCUIT
REPLACE
INTEST
REPEAT
FIELD
LINK
WIRE
TEST
GENERATOR,
BATTERY.
CONNEC-
WIRE
NO
REPAIR
OUTPUT
GENERATOR.
AGE
FUSE
WITH
TRAIN
VOLT-
CHECK
6
TEST
PCM
LINK.
YES
PERFORM
REPLACE
FOR
IF
THAN
ENGINE
CONNECTOR
CONTROL
WIRE
OHMS
CORROSION
LESS
HARNESS
5
PCM
OFF,
VOLTAGE
REPEAT
REPAIR
REFER
MODULE
CHECK
TO RESISTANCE
OR
PINOUTPUT
DROP
TO
TEST
DAMAGE
1POWER-
THAN
GREATER
IF
AT
ON
PIN
GROUP
NO
ING
OHMS
REPEAT
CONNECTOR
142
GENERATOR
6TEST
FROM
DIAGRAMS
5 8W,
CIRCUIT.
REPAIR
REPLACE
OUTPUT
PIN
YES
GENERATOR
WIR-
WITH
MEASURE
CUIT
AGE
PIN
A142
VOLT-
LESS
VOLTAGE
TEST
10
ENGINE
VOLTS?
ON
VOLTAGE
THAN
REPAIR
MEASURE
THE
YES
YES
WITH
JUMPER
POSITIVE
CUIT
RUNNING,
GENERA-
AT
WIRE
CORROSION
DAMAGE
VOLTAGE
K-20
THAN
TERMINAL
TOR.
NAL
CIR-
ENGINE
VOLTAGE
NO
WIRE
POST
ONREFER
YES
VOLTS?
THE
NO
ON
FROM
OFF,
LESS
ON
AT
TO
AT
10
GENERATOR.
PIN
OR
TO
K-20
WIRE
4?
THE
A142
CONNECT
CHECK
BATTERY
ERATOR.
CHARGING
NOSTIC
TERMI-
GEN-
NO
CIRCUIT?
CIR-OPEN
NO
MANUAL
WIRE
K-20
DIAG-
VOLTAGE CHECK POWERTRAIN CON-
DROP ABOVE TROL MODULE PIN 4 FOR COR-
0.6 VOLTS? ROSION OR DAMAGE.
8C - 8 CHARGING SYSTEM JA
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code DRB Scan Tool Display Description of Diagnostic Trouble Code
Fig. 4
12* Battery Disconnect Direct battery input to PCM was disconnected within the
last 50 key-on cycles.
41** Generator Field Not An open or shorted condition detected in the generator
Switching Properly field control circuit.
46** Charging System Voltage Battery voltage sense input above target charging voltage
Too High during engine operation.
47** Charging System Voltage Battery voltage sense input below target charging during
Too Low engine operation. Also, no significant change detected in
battery voltage during active test of generator output.
55* N/A Completion of fault code display on Check Engine lamp.
*Check Engine lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle ignition key
as described in manual and observe code flashed by Check Engine lamp.
**Check Engine lamp will illuminate during enging operation if this Diagnostic Trouble Code was recorded.
8C - 10 CHARGING SYSTEM JA
DIAGNOSIS AND TESTING (Continued)
RETRIEVING DIAGNOSTIC TROUBLE CODES
To start this function, cycle the ignition switch ON-
OFF-ON-OFF-ON within 5 seconds. This will cause
any DTC stored in the PCM memory to be displayed.
The malfunction indicator (Check Engine) lamp will
display a DTC by flashing on and off. There is a
short pause between flashes and a longer pause
between digits. All DTC’s displayed are two-digit
numbers, with a four-second pause between codes.
An example of a DTC is as follows:
(1) Lamp on for 2 seconds, then turns off.
(2) Lamp flashes 4 times pauses and then flashes
1 time.
(3) Lamp pauses for 4 seconds, flashes 4 times,
pauses, then flashes 7 times.
(4) The two DTC’s are 41 and 47. Any number of
DTC’s can be displayed, as long as they are in mem- Fig. 6 Wire Connectors
ory. The lamp will flash until all stored DTC’s are (5) Remove nut holding B+ wire to terminal on
displayed, then it will flash a DTC 55 to indicate the back of generator.
test is complete. (6) Separate B+ wire from generator terminal.
(7) Remove nut holding top of generator to adjust-
ERASING DIAGNOSTIC TROUBLE CODES
able T-bolt (Fig. 7).
The DRB Scan Tool must be used to erase a DTC.
INSTALLATION
(1) Place generator in position on vehicle.
(2) Install bolt to hold bottom generator pivot to
lower mount.
Fig. 5 Removal/Installation of Battery Cables
(3) Install nut to hold top of generator to adjust-
able T-bolt.
(4) Place B+ wire in position on generator termi-
nal.
(5) Install nut to hold B+ wire to terminal on back
of generator.
(6) Connect the push-in field wire connector onto
back of generator.
GENERATOR
GENERATOR
3.0L ENGINE MOUNTING
ASSEMBLY
BRACKET MOUNT
GENERATOR
BRACKET
JA CHARGING SYSTEM 8C - 11
REMOVAL AND INSTALLATION (Continued)
(7) Install accessory drive belt, refer to Group 7, (5) Install bolt to hold top of generator to mount
Cooling System for proper procedures. bracket.
(8) Connect battery negative cable. (6) Install accessory drive belt, refer to Group 7,
(9) Verify generator charge rate. Cooling System for proper procedures.
(7) Install windshield wiper housing, refer to
GENERATOR—3.0L ENGINE Group 8K, Windshield Wipers and Washers for
proper procedures.
REMOVAL (8) Connect battery negative cable.
(1) Release hood latch and open hood. (9) Verify generator charge rate.
(2) Disconnect battery negative cable (Fig. 5).
(3) Remove windshield wiper housing, refer to GENERATOR—3.3/3.8 L ENGINE
Group 8K, Windshield Wipers and Washers for
proper procedures. REMOVAL
(4) Remove accessory drive belt, refer to Group 7, (1) Release hood latch and open hood.
Cooling System for proper procedures. (2) Disconnect battery negative cable (Fig. 5).
(5) Remove bolt holding top of generator to mount (3) Remove windshield wiper housing, refer to
bracket (Fig. 8). Group 8K, Windshield Wipers and Washers for
proper procedures.
(4) Remove accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(5) Remove bolt holding top of generator mount
bracket to engine air intake plenum (Fig. 9).
Fig. 8 Generator–3.0LEngine
(6) Remove bolt holding bottom of generator to
lower pivot bracket (Fig. 6).
(7) Disengage push-in field wire connector from
back of generator.
(8) Remove nut holding B+ wire terminal to back Fig. 9 GeneratorMounting Bracket
of generator. (6) Remove bolts holding outside of generator
(9) Remove B+ terminal from generator. mount bracket to generator mount plate.
(7) Remove bolt holding top of generator to mount
INSTALLATION
bracket.
(1) Place B+ terminal in position on generator.
(8) Remove generator mount bracket from vehicle.
(2) Install nut to hold B+ wire terminal to back of
(9) Rotate generator toward rear dash panel.
generator
(10) Disconnect the push-in field wire connector
(3) Connect the push-in field wire connector into
from back of generator (Fig. 8).
back of generator.
(11) Remove nut holding B+ wire terminal to back
(4) Install bolt to hold bottom of generator to lower
of generator.
pivot bracket.
(12) Separate B+ terminal from generator.
DEEP
IGNITION
MOUNT
GENERATOR
AC/HOSE
SOCKET
PLATE
PIVOT
COIL
8C - 12 CHARGING SYSTEM JA
REMOVAL AND INSTALLATION (Continued)
(13) Remove bolt holding bottom of generator to (4) Install nut to hold B+ wire terminal to back of
lower pivot bracket (Fig. 10). generator.
(5) Connect the push-in field wire connector into
back of generator.
(6) Rotate generator forward away from dash
panel.
(7) Place generator mount bracket in position on
vehicle.
(8) Install bolt to hold top of generator to mount
bracket.
(9) Install bolts to hold outside of generator mount
bracket to generator mount plate.
(10) Install bolt to hold top of generator mount
bracket to engine air intake plenum.
(11) Install accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(12) Install windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
Fig. 10 Generatorpivot Bolt (13) Connect battery negative cable.
(14) Remove generator from vehicle (Fig. 11). (14) Verify generator charge rate.
INSTALLATION
(1) Connect electrical connector to sensor.
(2) Install screw and tighten.
(3) Lower vehicle.
SPECIFICATIONS
GENERATOR
Type Part Number Amperage output
Nippondenso 90 A HS 4686098 86 Amp
Nippondenso 120 A HS 4686099 98 Amp
TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt . . . . . . 14 N·m (125 in. lbs.)
Generator Mounting Bolts . . . . . 54 N·m (40 ft. lbs.)
Generator B+ Terminal . . . . . . . . 9 N·m (75 in. lbs.)
Starter Mounting Bolts . . . . . . . . 54 N·m (40 ft. lbs.)
Starter Solenoid Battery Nut . . . 10 N·m (90 in. lbs.)